Toner compositions for dry-powder electrophoretic displays

ABSTRACT

Toner particles and a dry-powder electrophoretic display employing such particles are disclosed herein. The toner particles adapted for a dry-powder electrophoretic display comprise emulsion/aggregation particles having a negative charge. At least a portion of the toner particles include a surface coating, comprising a methacrylate polymer, disposed on the surface of the toner particles to impart a positive charge to a set of toner particles. The emulsion/aggregation toner particles have a particle size generally less than about 10 micrometers that allows for improved image quality as compared to conventional toners utilized in dry-powder electrophoretic displays.

This is a divisional of application of U.S. Ser. No. 10/973,544, filedOct. 26, 2004, entitled “Toner Compositions for Dry-PowderElectrophoretic Displays”, by Naveen Chopra et al., the disclosure ofwhich is hereby incorporated by reference in its entirety.

BACKGROUND

The present disclosure relates, in various exemplary embodiments, totoner compositions and processes for producing the same. The presentdisclosure also relates to dry-powder electrophoretic displays employingsuch toner compositions.

Photo-electrophoretic imaging systems and electrophoretic displays areknown in the art. Electrophoretic imaging systems and displays generallyinclude electrically photosensitive pigment particles dispersed in acarrier liquid, or suspending fluid, and arranged between two paralleland generally transparent conducting electrode panels.

Conventional electrophoretic display systems are typically one of twotypes, namely, a one particle system or a two particle system. In a oneparticle system, the suspending fluid is colored with a dye. In a twoparticle system, two types of particles of different colors and oppositecharge are dispersed in a clear fluid. Particles acquire their chargevia the adsorption of polymeric charge control agents (CCAs) that areadded to the fluid. Under the influence of an electric field, thecharged particles migrate towards the oppositely charged electrode.

The particles are typically prepared using a liquid toner process tocreate composite particles consisting of a pigment and a resin. Theparticles generally range from about 1 to about 10 micrometers in size.The resin used includes thermoplastics such as a poly(ethylene-co-vinylacetate) or a poly(ethylene-co-methacrylic acid). The particles are thenencapsulated in a microcapsule or a photopolymer structure to produce adisplay device.

Electrophoretic displays using these liquid systems, however, have anumber of drawbacks. In unencapsulated systems, for example, articlesthat make up the system tend to cluster and settle, which reduces theperformance and the life of the electrophoretic display. Encapsulatedsystems also experience performance problems over time. For example,above 60° C., the polymer becomes soft and sticky, which leads toparticle agglomeration and overall degradation in device performance.These problems limit the robustness of the materials packaging, andpreclude any device preparation steps, such as hot lamination.Additionally, the desorption of charge control agents from the particlesin the solution leads to decay of the electrophoretic mobility of theparticles.

As an alternative to conventional electrophoretic displays utilizingliquid systems, there is a growing interest in dry-powderelectrophoretic displays. Dry-powder electrophoretic displays as usedherein refers to electrophoretic displays wherein the toner particlesare not dispersed in a suspending fluid or encapsulated as is understoodin the art. Dry-power electrophoretic displays offer advantages overconventional liquid electrophoretic systems. An important aspect is thatthe solventless nature of the dry-powder display greatly reduces theloss of particle charge over time. Additionally, known dry-powderelectrophoretic displays are typically limited by the size of the tonerparticles, i.e., up to about 50 micrometers, employed in such systems.The use of large toner particles, however, often results in poor imagequality and visual graininess.

It is therefore desirable to provide a new dry-powder electrophoreticdisplay system. It is further desirable to provide toner compositionsand particles suitable for use in such a system.

BRIEF DESCRIPTION

The present disclosure provides, in various exemplary embodiments, a drytoner composition, and/or a dry-powder electrophoretic displayincorporating such a toner composition, that achieves one or more of theforegoing.

In one aspect, a toner composition is provided comprising negativelycharged emulsion aggregation part ices and a colorant. A surface coatingcomprising a polymer selected from methacrylate polymers orpolycarbonate polymers is disposed on a portion of the toner particles,wherein the surface coating imparts a positive charge characteristic tothe surface of the particles. The negatively and positively charged drytoner particles so produced are particularly beneficial for use indry-powder electronic displays.

In another aspect, the present disclosure provides a dry-powderelectrophoretic display comprising a pair of electrodes disposedopposite one another and a spacer layer disposed between the electrodesto define an air gap therebetween. Included in the air gap is a firstdry toner composition comprising a plurality of negatively charged tonerparticles of a first color, and a second dry toner compositioncomprising a plurality of toner particles of a different or second colorand a different or second charge. In this regard, the toner particles ofthe second dry toner composition are covered with a surface coating toimpact a positive charge. The surface coating is comprised of a polymerselected from methacrylate polymers or polycarbonate polymers. The firstand second dry toner compositions are included in the air gap to producea dry-powder electrophoretic display.

In still another aspect, the present disclosure provides a dry-powderelectrophoretic display that comprises a cell having a viewed region anda non-viewed region. The cell contains a plurality of first tonerparticles comprising a resin and a colorant and having a negativecharge, and a plurality of second toner particles comprising a resin anda second colorant. The colorants of the first toner particles and thesecond toner particles differ from one another. A surface coating isdisposed on the outer surface of the second toner particles, wherein thesurface coating comprises a methacrylate polymer and imparts a positivecharge.

In yet another aspect, the present disclosure provides a dry-powderelectrophoretic display that comprises a first electrode, a secondelectrode disposed opposite the first electrode, a spacer layer disposedbetween the first and second electrodes and creating an air gaptherebetween, a first set of toner particles disposed between the firstand second electrodes, and a second set of toner particles disposedbetween the first and second electrodes. The first set of tonerparticles comprises a resin and a colorant, and has a negative charge.The second set of toner particles comprises a resin and a colorant andfurther comprises a surface coating in an amount of about 1 to about 10percent by weight of the toner particles to impact a positive charge. Anon-limiting example of such a surface coating is a methacrylate polymercomprising a copolymer ofbutylmethacrylate/(2-dimethylaminoethyl)methacrylate methylmethacrylate.

In a further aspect, the present disclosure provides a process forpreparing a dry toner composition for use in a dry-powderelectrophoretic display. The process comprises forming a first set ofdry toner particles comprising a resin and a colorant by an emulsionaggregation process, said first set of dry toner particles having anegative charge; and forming a second set of dry toner particlescomprising a resin latex and a colorant and an outer coating, saidsecond set of dry toner particles having a positive charge. Optionally,the second set of dry toner particles may be formed by heating a mixtureof a latex and a colorant at a temperature of below about the glasstransition temperature (Tg) of a polymer contained in the latex; andcooling the mixture; wherein said second set of dry toner particles isfurther wet surface treated with a methacrylate polymer by adding amethacrylate polymer solution to the mixture of the latex and colorantsubsequent to the cooling of the latex and colorant mixture, andadjusting the pH of the resulting solution to above about 7 therebypermitting the methacrylate polymer to precipitate on the tonerparticles, said methacrylate polymer providing a positive charge to thesurface of the toner particles of the second set of dry toner particles.

These and other aspects of the disclosure are more particularlydiscussed below.

BRIEF DESCRIPTION OF THE DRAWINGS

The following is a brief description of the drawings, which arepresented for the purposes of illustrating the disclosure describedherein and not for the purposes of limiting the same.

FIG. 1 is a schematic cross-section of an electrophoretic display inaccordance with one exemplary embodiment;

FIG. 2 depicts a series of cells containing toner particles in an airgap of a dry-powder electrophoretic display; and

FIG. 3 shows a top perspective of a sample portion of several cellsarranged in a grid or array.

FIG. 4 is a drawing illustratively representing the layering orprecipitation of EEPO on the surface of a toner particle.

DETAILED DESCRIPTION

The present disclosure, as illustrated in various exemplary embodiments,relates to dry-powder electrophoretic displays employing toner particlescomprising emulsion/aggregation particles. Generally, the dry-powderelectrophoretic displays include at least two sets of toner particles,wherein the color of one set of toner particles differs from the colorof the other sets of toner particles. Additionally, one set of tonerparticles has a charge opposite the charge of the other set of tonerparticles. That is, one set of toner particles carries a negativecharge, while the other set of toner particles carries a positivecharge. For example, one set of toner particles in the display includesnegatively charged emulsion/aggregation particles and the other set oftoner particles includes a surface coating to impart a positive chargeto the surface of the toner particles. The negatively and positivelycharged dry toner compositions so produced are particularly beneficialfor use in dry-powder electronic displays.

The present electrophoretic displays may have any configuration suitablefor use in a dry-powder electrophoretic display. Generally theelectrophoretic display includes a pair of electrodes disposed oppositeone another, an air gap between the electrodes, and two sets of tonerparticles of different colors and opposite charges disposed within theair gap and between the electrodes. In embodiment, the electrodes aresubstantially planar, and the opposing electrodes are substantiallyparallel to one another. The air gap is substantially free of anydispersions or suspending fluids that are typically present as inconventional electrophoretic displays. As used herein, the term “airgap” refers to a gap between the electrodes that comprises air or othersuitable gas such as, for example, argon. The dry-powder electrophoreticdisplay substantially free of a suspending liquid as is understood inthe art.

With reference to FIG. 1, an electrophoretic display 10 includes a pairof opposing, substantially parallel electrodes 12 a and 12 b. Two ormore spacer beads 14 are disposed between the electrodes 12 a and 12 bto separate the electrodes and provide an air gap 16 between the innersurfaces of the electrodes. Disposed between the electrodes are a so aplurality of toner particles 18 and 20.

The toner particles 18 and 20 are oppositely charged toner compositions.That is, one of toner particles 18 and 20 is negatively charged, and oneof toner particles 18 and 20 is positively charged. Additionally, thetoner particles 18 have a different color from the toner particles 20.There is no dispersion fluid between the electrode substrate, i.e.,within the air gap 16. As the charge of the electrodes 12 a and 12 b isreversed, the oppositely charged toner particles migrate across the airgap 16 in response to the electric field, creating a light or darkimage.

Referring to FIG. 2, a two-particle electrophoretic display 22 is shown,which consists of one particle species of a first color 24 (e.g. white)and another particle species of a second color 26 (e.g. black). Anoptically transmissive cell 28 surrounds the particles which aredispersed in an air gap 30 between the electrodes and substrates. Cells,such as cells 28, are used to prevent particle setting and particleagglomeration. The first and second particles 24, 26 differ from eachother optically and in terms of at least one other physicalcharacteristic that provides the basis for their separation. Forexample, the particles 24, 26 are colored differently and have differentsurface charges. As shown, the two-particle system consists of oneparticle species of a first white color 24 and another particle speciesof a second color 26, e.g., black, cyan, magenta, yellow, blue, red, orthe like. In one configuration, the colored particles 26 carry apositive charge, while the white colored particles 24 carry a negativecharge. The particle size can range from about 0.1 micron to about 20microns. In the absence of an electric field, the particles 24, 26 aresubstantially immobile. Further, in the absence of an electric field,the particles 24, 26 may be attracted to the surfaces by Van der Waalsforces or electrostatic forces.

As shown in FIG. 2, three cells 28 are displayed. It will be appreciatedthat any number of grids or arrays 32 of cells 28 may be arranged (referto FIG. 3). It is further appreciated that the actual display of acolored state 34 or a white color state 36 is accomplished bymanipulating the position of the particles 24, 26 in each cell 28 incorrespondence with the observing angle 38. As shown, the cells 28 arecubical in geometry. It will be further appreciated that any number ofgeometric configurations may be utilized. The cells 28 represent aspacer layer and may be made from a photopolymer (i.e. SU-8 distributedby Microchem Corp.). The cells may also be made by molding or embossing.The walls 38 of the cells 28 may be coated with a material that providesa desired surface energy to prevent excessive particle adhesion. Somelevel of particle adhesion is acceptable, and even desirable ifbistability of the display is required. The adhesion forces, howevershould be low enough so that particles can be removed from the surfaces,with a relatively low electric field For the electrophoretic displaysdescribed herein, the cell geometry is not essential. As an example, thevisible square viewing region 40, as shown in FIG. 3, is approximately200 microns along each side. The use of separate cells 28 preventsagglomeration and settling of the particles 24, 26.

Referring again to FIG. 2, an addressing scheme for controlling thecolor state of the display 22 is shown in which an electrode 42 (or setof electrodes) is adjacent a non-viewed region 44 (i.e. bottom or rearsurface or back-plane) of the cells 28 and another continuous topelectrode 46 is adjacent a viewed region 47 (i.e. top or front surface,or front-plane) of the cells 28. The top electrode 46 may take the formof an indium tin oxide coating (ITO) of a transparent glass substrate 48overlying the cell array 32. The glass substrate 48 may be similar tothose used in liquid crystal displays. The ITO top electrode 46 may beevaporated onto the top glass substrate 48. The ITO top electrode 46 istransparent, and the colored states 34, 36 are viewed through the ITOtop electrode 46.

Underlying the cell array 32 is a glass bottom substrate 50. It will beappreciated that any addressing scheme may be used in an electrophoreticdisplay in accordance with the present disclosure including, but notlimited to, a direct addressing scheme having a fixed electrode pattern,an active matrix addressing scheme with a pixilated electrode array, anda passive matrix addressing scheme with a top and bottom plate patternedin conductive stripes. For example, the bottom substrate 50 may be asilicon wafer or a printed circuit board (PCB) with patterned electrodesor an active matrix backplane. It will be appreciated that the top andbottom electrodes 42, 46 may also be formed from flexible material, suchas ITO coated Mylar™. Mylar™ is a registered trademark of E.I. DuPontCorporation, Wilmington, Del.

It will also be appreciated that the viewed and the non-viewed regionscan be arranged laterally (not shown) so that the non-viewed region(although observable) is significantly smaller in area with respect tothe viewed region (such as in laterally driven electrophoreticdisplays).

The electrodes of the electrophoretic display device may be any materialsuitable for such devices. At least one of the electrodes, and inparticular at least the top or upper electrode through which the imagesformed by the device must be viewed, should be transparent in order toenable such viewing. The bottom or back electrode does not have to betransparent but may be, for example, a light reflecting or lightabsorbing material. Suitable materials for the include but are notlimited to glass substrates, conductive plastic films and the like. Forexample, the electrode may be plastic films coated with indium tin oxide(ITO) such as polyethelyne terephthalate (PET) films, conductive glassfilms, such as ITO coated glass film, and conductive thin metals. Fortransparency, ITO coated plastic and glass films are typically used. Theelectrodes or conductive substrates may be coated with an insulatingpolymer or a polymer with a particular surface energy, tailored to meeta use's particular needs, to provide the appropriate or desired amountof particle adhesion.

The spacers may be any suitable material for a spacer andelectrophoretic display, and may be shaped in any suitable spacerdesign. In embodiments, the spacer is made from fiber materials.

The spacers separate the electrodes and provide an air gap between theelectrodes in which the toner particles are allowed to move or migrate.The spacers are sized to provide an acceptable air gap to allow theelectrophoretic device to properly function. The size of the air gapdepends on the voltage required to drive the particles back and forthbetween the electrodes. The size of the air gap is also based on theparticle size of the toner. For operating at low voltages, the gapshould be as small as possible, but yet still allow multi-layer stackingof the toner particles for good area coverage. Generally, the air gapshould be at least 3-10 times the diameter of the particles to allow forsatisfactory particle mobility and significant area coverage. Inembodiments, the air gap in the present dry-powder electrophoreticdevices is from about 3 to about 200 micrometers. In other embodiments,the air gap is from about 20 to about 75 micrometers.

The toner particles are comprised of emulsion/aggregation particles, andcomprise a polymer or polymer mix, a colorant, and optionally a wax.Emulsion/aggregation particles are particles prepared byemulsion/aggregation processes. In emulsion/aggregation processes,particles are achieved via aggregation as opposed to particle sizereduction. Emulsion/aggregation processes include the steps of emulsion,aggregation, coalescence, washing, and drying. Emulsion/aggregationprocesses for the preparation of toners are illustrated in a number ofXerox patents, including U.S. Pat. No. 5,290,654; U.S. Pat. No.5,278,020; U.S. Pat. No. 5,308,734; U.S. Pat. No. 5,370,963; U.S. Pat.No. 5,344,738; U.S. Pat. No. 5,403,693; U.S. Pat. No. 5,418,180; U.S.Pat. No. 5,364,729; and, U.S. Pat. No. 5,346,797, the disclosures ofwhich are incorporated in their entireties herein by reference.

The use of emulsion/aggregation particles as toner particles isadvantageous in that emulsion/aggregation particles have a very narrowparticle size distribution which provides more uniform movement of theparticles within the system, less likelihood of agglomeration problemsduring operation of the electrophoretic display, and better displayquality.

The resin polymers used to form the toner particles are not limited inany manner, and any material suitable for use in forming a tonerparticle may be used. Generally, the emulsion/aggregation process is notlimited in the use of certain polymers. Examples of materials suitableto form the toners include, but are not limited to, polyesters,polyamides, polyimides, polyethelynes, polypropylenes, polyisobutyrates,acrylic based polymers, such as styrene acrylate, and styrenemethacrylate, styrene butadiene, polyester-imide, ethylene-vinyl acetatecopolymer, and the like.

Suitable polyester resins include, but are not limited to, polyesterSPE2, available from Hercules Chemical, and polyesters of the formula:

wherein Y is an alkali metal, X is a glycol, and n and m each representthe number of segments.

In embodiments suitable polyester resins include, but are not limitedto, salts ofcopoly(1,2-propylene-dipropylene-5-sulfoisophthalate)-copoly(1,2-propylene-dipropyleneterephthalate),copoly(1,2-propylene-diethylene-5-sulfoisophthalate)-copoly(1,2-propylene-diethyleneterephthalate),copoly(propylene-5-sulfoisophthalate)-copoly(1,2-propyleneterephthalate),copoly(1,3-butylene-5-sulfoisophthalate)-poly(1,3-butyleneterephthalate), poly(butylenesulfoisophthalate)-copoly 1,3-butyleneterephthalate, and the like. Illustrative examples of suitable polyesterresins include the beryllium salt ofcopoly(1,2-propylene-dipropylene-5-sulfoisophthalate)-copoly(1,2-propylene-dipropyleneterephthalate), the barium salt ofcopoly(1,2-propylene-diethylene-5-sulfoisophthalate)-copoly(1,2-propylene-diethyleneterephthalate), the magnesium salt of copoly(1,2dipropylene-5-sulfoisophthalate)-copoly(1,2-propylene terephthalate),the magnesium salt ofcopoly(1,3-butylene-5-sulfoisophthalate)-copoly(1,3-butyleneterephthalate), the calcium salt of copoly(1,2dipropylene-5-sulfoisophthalate)-copoly(1,2-propylene terephthalate),the calcium salt ofcopoly(1,3-butylene-5-sulfoisophthalate)-copoly(1,3-butyleneterephthalate), the cobalt salt ofcopoly(1,2-propylene-diethylene-5-sulfoisophthalate)-copoly(1,2-propylene-diethylene terephthalate), the nickel salt of copoly(1,2dipropylene-5-sulfoisophthalate)-copoly(1,2-propylene terephthalate),the iron salt ofcopoly(1,3-butylene-5-sulfoisophthalate)-copoly(1,3-butyleneterephthalate), the zirconium salt ofcopoly(1,2-dipropylene-5-sulfoisophthalate)-copoly(1,2-propyleneterephthalate), the chromium salt ofcopoly(1,3-butylene-5-sulfoisophthalate)-copoly(1,3-butyleneterephthalate), and the like.

Additionally, the polyester resin may be the resins described in U.S.Pat. Nos. 6,593,049, and 6,756,176, the entire disclosures of which areincorporated herein by reference. The toners may also comprise a mixtureof an amorphous polyester resin and a crystalline polyester resin asdescribed in copending U.S. Ser. No. 10/349,548, which is published asU.S. Patent Application No. U.S. 2004/0142266, the entire disclosure ofwhich is incorporated herein by reference.

Examples of latex resins or polymers suitable for use in toner particlesinclude, but are not limited to, poly(styrene-butadiene),poly(methylstyrene-butadiene), poly(methyl methacrylate-butadiene),poly(ethyl methacrylate-butadiene), poly(propyl methacrylate-butadiene),poly(butyl methacrylate-butadiene), poly(methyl acrylate-butadiene),poly(ethyl acrylate-butadiene), poly(propyl acrylate-butadiene),poly(butyl acrylate-butadiene), poly(styrene-isoprene),poly(methylstyrene-isoprene), poly(methyl methacrylate-isoprene),poly(ethyl methacrylate-isoprene), poly(propyl methacrylate-isoprene),poly(butyl methacrylate-isoprene), poly(methyl acrylate-isoprene),poly(ethyl acrylate-isoprene), poly(propyl acrylate-isoprene),poly(butyl acrylate-isoprene); poly(styrene-propyl acrylate),poly(styrene-butyl acrylate), poly(styrene-butadiene-acrylic acid),poly(styrene-butadiene-methacrylic acid),poly(styrene-butadiene-acrylonitrile-acrylic acid) poly(styrene-butylacrylate-acrylic acid), poly(styrene-butyl acrylate-methacrylic acid),poly(styrene-butyl acrylate-acrylononitrile), and poly(styrene-butylacrylate-acrylononitrile-acrylic acid). In embodiments, the resin orpolymer is a styrene/butyl/acrylic acid terpolymer. Cross linked resinsare prepared by incorporating an addition monomer such as divinylbenzene during the synthesis of the above latex resins or polymers

The toner particles may include any suitable colorant. Suitablecolorants include, but are not limited to dyes, pigments, and mixturesthereof. The colorant is generally present in an amount of from about 1to about 65% by weight of the toner. In embodiments, the colorant ispresent in an amount of from about 2 to about 35% by weight of thetoner, and in other embodiments in an amount of from about 3 to about15% by weight of the toner. To form black toner particles, the colorantmay be, but is not limited to, carbon black, magnetites, surface treatedmagnetites, and the like. White toner particles may be prepared by theuse of titanium dioxide, aluminum oxide, zirconium oxide, zinc dioxide,and the like. Colored particles may be prepared by using coloredpigments or dyes, such as, for example, cyan, magenta, yellow, red,green, brown, blue, or mixtures thereof.

Suitable colorants include black colorants like REGAL 330®; magnetites,such as Mobay magnetites MO8029™, MO8060™; Columbian magnetites; MAPICOBLACKS™ and surface treated magnetites; Pfizer magnetites CB4799™,CB5300™, CB5600™, MCX6369™; Bayer magnetites, BAYFERROX 8600™, 8610™;Northern Pigments magnetites, NP-604™, NP-608™; Magnox magnetitesTMB-100™, or TMB-104™; and the like. Suitable colored pigments orcolorants include, but are not limited to, cyan, magenta, yellow, red,green, brown, blue colorants or mixtures thereof. Specific examples ofpigments include phthalocyanine HELIOGEN BLUE L6900™, L7020™, D6840™,D7080™, D7020™, K6910™, and K7020™, available from BASF, PYLAM OILBLUE™, PYLAM OIL YELLOW™, PIGMENT BLUE 1™ available from Paul Uhlich &Company, Inc., PIGMENT VIOLET 1™, PIGMENT RED 48™, LEMON CHROME YELLOWDCC 1026™, E.D. TOLUIDINE RED™ and BON RED C™ available from DominionColor Corporation, Ltd., Toronto, Ontario, NOVAPERM YELLOW FGL™,HOSTAPERM PINK E™ from Hoechst, and CINQUASIA MAGENTA™ available fromE.I. DuPont de Nemours & Company, and the like. Generally, colorantsthat can be selected are black cyan, magenta, or yellow, and mixturesthereof. Examples of magentas are 2,9-dimethyl-substituted quinacridoneand anthraquinone dye identified in the Color index as CI 60710, CIDispersed Red 15, diazo dye identified in the Color Index as CI 26050,CI Solvent Red 19, and the like. Illustrative examples of cyans includecopper tetra(octadecyl sulfonamido) phthalocyanine, x-copperphthalocyanine pigment listed in the Color Index as CI 74160, CI PigmentBlue, and Anthrathrene Blue, identified in the Color Index as CI 69810,Special Blue X-2137, and the like; while illustrative examples ofyellows are diarylide yellow 3,3-dichlorobenzidene acetoacetanilides, amonoazo pigment identified in the Color Index as CI 12700, CI SolventYellow 16, a nitrophenyl amine sulfonamide identified in the Color Indexas Foron Yellow SE/GLN, CI Dispersed Yellow 332,5-dimethoxy-4-sulfonanilide phenylazo-4′-chloro-2,5-dimethoxyacetoacetanilide, and Permanent Yellow FGL. Colored magnetites, such asmixtures of MAPICO BLACK™, and cyan components may also be selected ascolorants. Other known colorants can be selected, such as Levanyl BlackA-SF (Miles, Bayer) and Sunsperse Carbon Black LHD 9303 (Sun Chemicals),Paliogen Black L9984 9BASF), Pigment Black K801 (BASF) and particularlycarbon blacks such as REGAL 330, REGAL 660 (Cabot), Carbon Black 5250and 5750 (Columbian Chemicals), and colored dyes such as Paliogen Violet5100 and 5890 (BASF), Normandy Magenta RD-2400 (Paul Uhlrich), PermanentViolet VT2645 (Paul Uhlrich), Heliogen Green L8730 (BASF), Argyle GreenXP-111-S (Paul Uhlrich), Brilliant Green Toner GR 0991 (Paul Uhlrich),Lithol Scarlet D3700 (BASF), Scarlet for Thermoplast NSD Red (Aldrich),Neopen Blue FF4012 (BASF), Sudan Blue OS (BASF), PV Fast Blue B2G01(American Hoechst), Sunsperse Blue BHD 6000 (Sun Chemicals), IrgaliteBlue BCA (Ciba-Geigy), Paliogen Blue 6470 (BASF), Sudan II (Matheson,Coleman, Bell), Sudan III (Matheson, Coleman, Bell), Sudan IV (Matheson,Coleman, Bell), Sudan Orange G (Aldrich), Sudan Orange 220 (BASF),Paliogen Orange 3040 (BASF), Ortho Orange OR 2673 (Paul Uhlich),Paliogen Yellow 152, 1560 (BASF), Lithol Fast Yellow 0991K (BASF),Paliotol Yellow 1840 (BASF), Neopen Yellow (BASF), Novoperm Yellow FG 1,and FGL (Hoechst), Permanent Yellow YE 0305 (Paul Uhlich), LumogenYellow D0790 (BASF), Sunsperse Yellow YHD 6001 (Sun Chemicals),Suco-Gelb L1250 (BASF), Suco-Yellow D1355 (BASF), Sico Fast YellowD1165, D1355, and D1351 (BASF), Hostaperm Pink E (American Hoechst),Fanal Pink D4830 (BASF), Cinquasia Magenta (DuPont), Lithol ScarletD3700 (BASF), Toluidine Red (Aldrich), Scarlet for Thermoplast NSD PS PA(Ugine Kuhlmann of Canada), E.D. Toluidine Red (Aldrich), Lithol RubineToner (Paul Uhlich) Lithol Scarlet 4440 (BASF), Bon Red C (DominionColor Company), Royal Brilliant Red RD-8192 (Paul Uhlich), Oracet PinkRF (Ciba-Geigy), Paliogen Red 3871K (BASF), Paliogen Red 3340 (BASF),and Lithol Fast Scarlet L4300 (BASF). Additional useful colorantsinclude pigments in water based dispersions such as those commerciallyavailable from Sun Chemical, for example SUNSPERSE BHD 6011X (Blue 15Type), SUNSPERSE BHD 9312X (Pigment Blue 15 74160), SUNSPERSE BHD 6000X(Pigment Blue 15:3 74160), SUNSPERSE GHD 9600X and GHD 6004X (PigmentGreen 7 74260), SUNSPERSE QHD 6040X (Pigment Red 122 73915), SUNSPERSERHD 9668X (Pigment Red 185 12516), SUNSPERSE RHD 9365X and 9504X(Pigment Red 57 15850:1, SUNSPERSE YHD 6005X (Pigment Yellow 83 21108),FLEXIVERSE YFD 4249 (Pigment Yellow 17 21105), SUNSPERSE YHD 6020X and6045X (Pigment Yellow 74 11741), SUNSPERSE YHD 600X and 9604X (PigmentYellow 14 21095), FLEXIVERSE LFD 4343 and LFD 9736 (Pigment Black 777226) and the like or mixtures thereof. Other useful water basedcolorant dispersions include those commercially available from Clariant,for example, HOSTAFINE Yellow GR, HOSTAFINE Black T and Black TS,HOSTAFINE Blue B2G, HOSTAFINE Rubine F6B and magenta dry pigment such asToner Magenta 6BVP2213 and Toner Magenta EO2 which can be dispersed inwater and/or surfactant prior to use. The white pigment may be chosenfrom compound such as, for example, titanium dioxide, aluminum oxide,zirconium oxide and zinc dioxide.

Any suitable effective positive or negative charge enhancing additivecan be selected for the toner compositions of the present disclosure.Such additives may be present in embodiments, in an amount of about 0.1to about 10, and, in other embodiments, may be present in an amount ofabout 1 to about 3 percent by weight. Examples of these additivesinclude quaternary ammonium compounds inclusive of alkyl pyridiniumhalides; alkyl pyridinium compounds, reference U.S. Pat. No. 4,298,672,the disclosure of which is totally incorporated hereby by reference;organic sulfate and sulfonate compositions, reference U.S. Pat. No.4,338,390, the disclosure of which is totally incorporated hereby byreference; cetyl pyridinium tetrafluoroborates; distearyl dimethylammonium methyl sulfate; aluminum salts such as BONTRON E84™ or E88™(Hodogaya Chemical); and the like.

In embodiments, the process for forming the toner particles may include(i) providing a coolant dispersion comprising a colorant, water, anionic surfactant, a nonionic surfactant or mixtures of an ionicsurfactant and a nonionic surfactant, and providing a latex emulsioncomprising a resin, a nonionic surfactant and an ionic surfactant; (ii)blending the colorant dispersion with the latex emulsion, resin, anonionic surfactant and an ionic surfactant and optionally adding a waxdispersion comprised of, for example, submicron particles in thediameter size range of from about 0.1 to about 0.4 micron dispersed inan ionic surfactant of the same charge polarity as that of the ionicsurfactant in the colorant dispersion or latex emulsion; (iii) heatingthe resulting mixture below about, or about equal to the glasstransition temperature (T_(g)) of the latex resin to form toner sizedaggregates; and (iv) heating the resulting aggregate suspension aboveabout the Tg of the latex resin. A surface coating as described herein,for example, a methacrylate copolymer, available from Rohm American Inc.as EUDRAGIT®, may be added to the above mixture and a toner whichcontains a surface coating, such as the methacrylate copolymer, may beisolated.

In other embodiments, the process may include (i) providing orgenerating a latex emulsion of resin, water, and an ionic surfactant,and providing or generating a colorant dispersion containing a colorant,water, an ionic surfactant, or a nonionic surfactant; (ii) optionallyproviding or generating a wax dispersion containing an anionicsurfactant similarly charged to that of the latex surfactant emulsion;(iii) blending the wax dispersion (if used) with the colorantdispersion; (iv) heating the resulting mixture below the glasstransition temperature (Tg) of the latex resin; (v) heating (iv) aboveabout the Tg of the latex resin; (vi) adding a surface coating asdescribed herein, such as, for example a methacrylate copolymer,available from Rohm American Inc. as EUDRAGIT®, in an amount of fromabout 3 to about 7 weight percent; (vii) retaining the mixture (vi) at atemperature of from about 70° C. to about 95° C. for about 3 to about 10hours; (vii) retaining the mixture (vi) at a temperature of from about70° C. to about 95° C. for about 3 to about 10 hours; (viii) washing theresulting toner slurry; and (ix) isolating the toners.

The process may include adding an additional latex wherein the addedlatex contains the same resin as the initial latex, or wherein the addedlatex contains a dissimilar resin as compared to that of the initiallatex resin.

In embodiments, aggregation of the latex resin and colorant may beaccomplished by heating at a temperature below the glass transitiontemperature of the resin or polymer contained in the latex andcoalescence may be accomplished by heating at a temperature of about theglass transition temperature of the polymer contained in the latex toenable fusion or coalescence of colorant and latex resin, followed bymixing of the composition resulting with a surface coating solution,such as a methacrylate copolymer. In embodiments, the aggregationtemperature may be from about 45° C. to about 55° C., and thecoalescence temperature may be from about 75° C. to about 97° C. Instill other embodiments, the aggregation temperature is from about 50°C. to about 60° C., and the coalescence temperature is from about 80° C.to about 95° C.

In embodiments, the latex emulsion comprises submicron resin particlesin the size range of about 100 to about 500 nanometers, and morespecifically, in the size range of about 100 to about 500 nanometers,and more specifically, in the size range of about 150 to about 400nanometers in water and an ionic surfactant, and more specifically, ananionic surfactant; the colorant dispersion comprises submicron pigmentparticles of about 50 to about 250 nanometers and more specifically, ofabout 80 to about 200 nanometers in size diameter; a first coagulantcomprising of a poly halide such as poly Aluminum chloride (PAC) or polyaluminum sulfosilicate (PASS) and optionally a second coagulant such asa cationic surfactant comprising, for example, dialkyl benzenealkylammonium chloride, lauryl trimethyl ammonium chloride, alkylbenzylmethyl ammonium chloride, alkyl benzyl dimethyl ammonium bromide,benzalkonium chloride, cetyl pyridinium bromide, C₁₂, C₁₅, C₁₇ trimethylammonium bromides, halide salts of quaternized polyoxyethylalkylamines,dodecylbenzyl triethyl ammonium chloride, and which coagulant surfactantcomponent is selected in an amount of, for example, from about 0.01 toabout 10 percent by weight of toner; during or subsequent to heating, asecond latex is added, and which latex is comprised of submicron resinparticles suspended in an aqueous phase containing an ionic surfactant,and wherein the second latex is optionally selected in an amount ofabout 15 to about 35 percent by weight of the initial latex.

In other embodiments, the second latex is added and enables formation ofa coating on the resulting toner aggregates of (v), and wherein thethickness of the formed coating is from about 0.1 to about 1 micron.

In embodiments, for example, white toner particles are prepared byaggregating dispersions of a styrene butylacrylate, carboxylic acidterpolymer, non cross-linked resin particles, a second cross-linkedcopolymeric resin of styrene/butylacrylate/carboxylic acid divinylbenzene, and a titanium dioxide pigment in the presence of two cationiccoagulants to provide aggregates. The aggregates have a particle size ofabout 5.7 micrometers. The aggregates are then coalesced at temperaturesabove the glass transition temperature of the non cross-linked resin toprovide spherical particles of 5.7 micrometers with a GSD of about 1.22.Particles are then washed four times with dionized water and dried.Color toners may be prepared in a similar manner, but with the use of adifferent pigment to provide the appropriate or desired color.

In embodiments, toner particles, may be prepared by a process thatincludes

(i) blending a latex emulsion with a colorant dispersion comprised ofsubmicron, about for example 0.05 to about 1 micron in diameter,particles suspended in a nonionic surfactant and water, and optionallyadding a wax dispersion comprised of submicron wax particles dispersedin an ionic surfactant of a similar charge polarity to that of the ionicsurfactant in the latex emulsion, and wherein the latex containssubmicron resin particles, an ionic surfactant and water;

(ii) adding to the blend two coagulants of a polymetal halide dissolvedin a strong acid and an ionic surfactant of opposite charge polarity tothat of the latex surfactant and pigment ionic surfactant to initiateflocculation of the latex and the white particles;

(iii) heating the resulting mixture below the glass transitiontemperature (Tg) of the latex resin to form toner sized aggregates;

(iv) optionally adding a latex to the formed toner aggregates;

(v) adjusting the pH of the toner aggregates from about 1.8 to about 3to a pH value of about 6.5 to about 8 with a base;

(vi) heating the resulting aggregate suspension of (v) to above the Tgof the latex resin;

(vii) retaining the temperature of the mixture (vi) from about 70 toabout 95° C., followed by a reduction of the pH to about 4.8 to about 6,and then optionally retaining the temperature for a period of about 0.5to about 6 hours; and

(viii) cooling the reactor contents and isolating the particles, bywashing, and drying.

In another embodiment, a process for the preparation of tonercompositions comprises.

(i) preparing an emulsion latex comprised of sodio sulfonated polyesterresin particles of from about 5 to about 500 nanometers in size diameterby heating said resin in water at a temperature of from about 65° C. toabout 90° C.

(ii) preparing a pigment dispersion in water by dispersing in water fromabout 10 to about 25 weight percent of sodio sulfonated polyester andfrom about 1 to about 5 weight percent of pigment;

(iii) adding the pigment dispersion to a latex mixture comprised ofsulfonated polyester resin particles in water with shearing, followed bythe addition of a divalent salt dissolved in water until aggregationresults as indicated by an increase in the latex viscosity of from about2 centipoise to about 100 centipoise;

(iv) heating the resulting mixture at a temperature of from about 45° C.to about 55° C. thereby causing further aggregation and enablingcoalescence, resulting in toner particles of from about 4 to about9icrons in volume average diameter and with a geometric distribution ofless than about 1.3; and optionally

(v) cooling the product mixture to about 25° C. and followed by washingand drying.

The present dry-powder electrophoretic displays comprise two sets ofoppositely charged toners. Namely, one set of toner particles isnegatively charged and the other set is positively charged. As usedherein, a set of toner particles refers to a plurality of tonerparticles of the same color. A set of toner particles, has, inembodiments, the same general composition and pigment/colorant makeup.As described herein, the toner particles are generallyemulsion/aggregation particles. Emulsion/aggregation particles aretypically negatively charged. Therefore, at least one set of the tonerparticles needs to be treated to impart a positive charge to theparticles. Along these lines, a surface coating is disposed on orapplied to the surface of at least one set of the toner particles, andin embodiments to the colored toner particles in an electrophoreticdisplay employing white toner particles and colored toner particles.Generally, the surface coating should be optically transparent, capableof forming a uniform film, and must also be a non-conductive material.Materials suitable as the surface coating include, but are not limitedto, polycarbonate, and methacrylate copolymers.

A suitable methacrylate copolymer is available from Rohm American Inc.as EUDRAGIT®. The methacrylate copolymer is, in embodiments,butylmethacrylate-(2-dimethylaminoethyl)methacrylate-methylmethacrylatecopolymer (1:2:1). The methacrylate copolymer can be dispersed in water.The copolymer possesses an average particle size diameter of forexample, from about 50 to about 500 nanometers (nm). In embodiments, thecopolymer possesses an average particle size of from about 100 to about300 nanometers (nm).

Examples of specific polymers that may be selected are EUDRAGIT® RL andRS polymers (Rohm Pharma) which are copolymers synthesized from acrylicand methacrylic esters with a low content of quaternary ammonium groups.EUDRAGIT® RL and RS differ in the molar ratios of the ammonium groups tothe remaining neutral (meth)acrylic acid esters (1:20 and 1:40respectively). EUDRAGIT® NE polymers are an aqueous dispersion of aneutral copolymer based on ethyl acrylate and methyl methacrylate.EUDRAGIT® RD 100 is the powder form of copolymers of acrylate andmethacrylates with a quaternary ammonium group in combination withsodium carboxymethylcellulose.

Various suitable effective amounts of the methacrylate copolymerincluding, for example, the copolymer available from Rohm American Inc.as EUDRAGIT®, can be selected. Generally, the surface coating materialshould be present in an effective amount to provide a surface coatingthat is from about 1 to about 10 percent by weight of the tonercomposition. As used herein, the weight of the surface coating refers tothe percent by weight of the coating on each toner particle in the tonercomposition. In embodiments, the surface coating material should bepresent in an effective amount to provide a surface coating that is fromabout 3 to about 7 percent by weight of the toner composition.

The surface coating may be disposed on or coated on the toner particlesby any suitable method. Suitable methods for forming surface coatedtoners, and particularly toners coated with a methacrylate polymer suchas, for example, Eudragit® polymers, are described in U.S. patentapplication Ser. No. 10/446,015 filed on May 27, 2003, the entiredisclosure of which is incorporated herein by reference. In embodiments,the surface coating material is added in its dissolved form to anacidified slurry of toner particles. The pH of the slurry is thenadjusted so that the surface coating material precipitates on thesurface of the toner. Without being bound to any particular theory, itis believed that a film of the surface coating is formed on the surfaceof the toner particles upon the evaporation of the water. By theformation of the surface coating film, the surface of the toner acquiresthe (cationic) characteristics of the surface treatment additive, whichresults in a positively charged toner.

In embodiments, the cationic polymer is a EUDRAGIT® series polymer, suchas, for example, EUDRAGIT® EPO (hereinafter “EEPO”), which is reversiblysoluble-insoluble in aqueous solution when the pH is changed and,therefore, the solubility of EEPO can be considered pH-dependent. TheEEPO becomes water soluble via salt formation with acids and can beadded in this form to the acidic toner slurry. It is hypothesized thatthe water-soluble polymer would interact in solution with the tonerparticles even at low pH. Once the polymer has time to adsorb to thetoner particles, the pH can be shifted to basic conditions. At thispoint the polymer will precipitate onto the toner's surface and form afilm around the toner upon the evaporation of water. The surface of thetoner is hypothesized to acquire the cationic characteristics of thepolymer resulting in a positive charged toner.

More specifically, in embodiments, the EEPO polymer contains tertiaryamino functional groups capable of ionic interactions with, for example,sulfonated groups on the surface of the polyester toner. The neighboringpolymer chain and toner particle surface become complexed to one anotherresulting, in a modification of the properties of the particle surfaceand thus the tribocharging characteristics. The surface treatmentapproach, in embodiments, is to add the polymer in its dissolved form tothe toner slurry following the toner fabrication process. The tonerslurry is adjusted to a pH of for example from about 2 to about 3 topermit the EEPO to remain dissolved during the addition period. It ishypothesized that the water-soluble polymer interacts with the tonerparticles via electrostatic attraction, even at low pH, and will notsubstantially precipitate or irreversibly complex to each other. Oncethe pH is increased to from about 10 to about 12, the EEPO willprecipitate onto the toner surface and form a film or layer ofpositive-charged polymeric material around the toner surface.Evaporating the water from the toner by for example, freeze drying thetoner particles promotes further coalescence of the polymeric film tothe toner surface. This process is illustratively represented in FIG. 4.

In embodiments employing a set of white toner particles and a set ofcolored or black toner particles, the white toner particles typicallycarry a negative charge, and the colored or black toner particlestypically include a surface coating as described herein. In embodimentsemploying two different colored toners, any toner may be the negativelycharged toner and any toner may be treated with a surface coating asdescribed herein.

In embodiments, the toner particles have a particle size of less thanabout 20 micrometers. In other embodiments, the toner particles have aparticle size of from about 1 to about 20 micrometers. In furtherembodiments, the toner particles have a particle size of about 1 toabout 10, and may be from about 4 to about 7 micrometers.

In another preferred embodiment, the toner particles comprises a shapefactor of about 110 to about 130, where a shape factor of 100 is definedas a particle which is perfectly spherical in shape. The presentapplication would require that the particle be as spherical in shape toreduce the drag, and hence provide easier movement on applying anelectrical field. In another preferred embodiment, the toner particlescomprises of a particle circularity of about 0.920 to about 0.980, asmeasured by the FPIA instrument, where a particle circularity of 1.00 isconsidered perfectly spherical.

The present toner particles may be used in a dry-powder electrophoreticdisplay. A dry-powder electrophoretic display, as used herein containseither no dispersion fluid or is substantially free of a dispersionfluid. Modifying the surface of the toners, such as with a surfacecoating as described herein, allows for selective tuning of the surfacecharge to be either positive or negative.

Two sets of oppositely charged dry toner particles are disposed betweentwo electrodes. The electrodes are separated by spacer beads whichcreate an air gap between the two electrodes. Generally, at least one ofthe two sets of toner particles includes a surface coating as describedherein to impart a positive charge to the set of toner particles. As thecharge on the electrodes is reversed, the oppositely charged tonerparticles migrate back and forth across the gap in response to theelectric field, thereby creating a light or dark image to the viewer.

Typically, to create an image, the electrodes or substrates areconnected to a voltage source. As the charge or an electrode is changed,the charged particles migrate toward the oppositely charged electrode.When a negative voltage is applied to the upper electrode or conductivesubstrate, the positively charged toner particles comprising the surfacecoating migrate to the upper electrode as conductive substrate to givean appearance corresponding to the color of the positively charged tonerparticles. When a positive charge is applied, the negatively chargedtoner particles, i.e., the toner particles without the surface coating,migrate toward the upper electrode or conductive substrate to provide acolor appearance corresponding to the color of the negatively chargedtoner particles. The color appearance will remain in a given state evenif a voltage is not applied.

The present exemplary embodiments are further illustrated by thefollowing examples. The examples are merely illustrative, and are notintended to be limiting in any manner.

EXAMPLES Example I Surface Treated Toners

Preparation of Sodio Sulfonated Polyesters:

A linear sulfonated random copolyester resin comprised of, on a molpercent basis, 0.465 of terephthalate, 0.035 of sodiumsulfoisophthalate, 0.475 of 1,2-propanediol, and 0.025 of diethyleneglycol was prepared as follows. In a 5 gallon Parr reactor equipped witha bottom drain valve, double turbine agitator, and distillation receiverwith a cold water condenser were charged 3.98 kilograms ofdimethylterephthalate, 451 grams of sodium dimethyl sulfoisophthalate,3.104 kilograms of 1,2-propanediol (1 mole excess of glycol), 351 gramsof diethylene glycol (1 mole excess of glycol), and 8 grams of butyltinhydroxide oxide catalyst. The reactor was then heated to 165° C. withstirring for 3 hours whereby 1.33 kilograms of distillate was collectedin the distillation receiver, and which distillate was comprised ofabout 98 percent by volume of methanol and 2 percent by volume of1,2-propanediol as measured by the ABBE refractometer available fromAmerican Optical Corporation. The reactor mixture was then heated to190° C. over a one hour period, after which the pressure was slowlyreduced from atmospheric pressure to about 260 Torr over a one hourperiod, and then reduced to 5 Torr over a two hour period with thecollection of approximately 470 grams of distillate in the distillationreceiver, and which distillate was comprised of approximately 97 percentby volume of 1,2-propanediol and 3 percent by volume of methanol asmeasured by the ABBE refractometer. The pressure was then furtherreduced to about 1 Torr over a 30 minute period whereby an additional530 grams of 1,2-propanediol were collected. The reactor was then purgedwith nitrogen to atmospheric pressure, and the polymer productdischarged through the bottom drain onto a container cooled with dry iceto yield 5.60 kilograms of 3.5 mol percent sulfonated polyester resin,sodio salt of(1,2-propylene-dipropylene-5-sulfoisophthalate)-copoly(1,2-propylene-dipropyleneterephthalate). The sulfonated polyester resin glass transitiontemperature was measured to be 56.6° C. (onset) utilizing the 910Differential Scanning Calorimeter available from E.I. DuPont operatingat a heating rate of 10° C. per minute. The number average molecularweight was measured to be 3,250 grams per mole, and the weight averagemolecular weight was measured to be 5,290 grams per mole usingtetrahydrofuran as the solvent.

Preparation of a Sodio Sulfonated Polyester Colloid Solution:

A 15 percent solids concentration of a colloidal solution ofsodio-sulfonated polyester resin particles with particle diameter sizesof from about 5 to about 150 nanometers, and typically about 20 to about40 nanometers dissipated in 85 percent aqueous media of water wasprepared by first heating about 2 liters of deionized water to about 85°C. with stirring, and adding thereto 300 grams of the above preparedsulfonated polyester resin, followed by continued heating at about 85°C., and stirring of the mixture for a duration of from about one toabout two hours, followed by cooling to about room temperature, about25° C. throughout the Examples. The colloidal solution ofsodio-sulfonated polyester resin particles possessed a characteristicblue tinge and particle sizes of from about 5 to about 150 nanometers,and typically of about 20 to about 40 nanometers, as measured by theNiCOMP® particle sizer.

Toner 1: Sodio Sulfonated Polyester Toner (Control, Untreated)

A pilot plant batch of toner comprised of a sodio-sulfonated polyester(SPE4, 12% solids and 88% deionized water), 9% Carnauba wax dispersionand 6%-wt of Flexiverse Blue (Pigment Blue 15:3, BFD1121, 47.1% solids)dispersion (Sun Chemical Co.) was prepared. Aggregation of the cyanpolyester toner particles was completed at 58° C. (degrees Centigradethroughout) in a 30-gallon stainless steel reactor (of which only 20 kgof the toner yield was used for bench scale studies). The agitation ratewas set initially to 100 RPM. A 5% zinc acetate solution was added asthe coagulant via the FIZA or fast initial zinc addition (FIZA)technique as illustrated in U.S. Pat. No. 6,395,445, where 60-80% of thetotal zinc acetate solution was added quickly (600 g/min for the first30 minutes) and the remainder (80-100 g/min thereafter) was added at areduced rate. The amount of zinc acetate added equaled approximately 11%of the total resin in the emulsion. After 7 hours of aggregation, theparticle size reached 5.24 μm with a GSD of 1.2. Full cooling wasapplied and particles were sieved at 30-35° C. through a 25 μm nylonfilter bag. A portion of the toner slurry was washed in the lab threetimes with deionized water after the mother liquor removal, resuspendedto approximately 25% weight solids and freeze-dried for 48 hours toprovide the untreated parent toner (VF173 or Control). This toner wascomprised of 85% sodio-sulfonated polyester, 9% Carnauba wax dispersionand 6%-wt of Flexiverse Blue pigment.

Toner 2: Treated Sodio Sulfonated Polyester Toner

Preparation of EEPO Solution

An aminoalkylmethacrylate copolymer called Eudragit EPO (EEPO), whichwas delivered to toner as a 1 percent (wt/wt) solution in deionizedwater (DIW), was prepared by dissolving 1.26 grams of the EEPO in 124.7grams of 0.3 M HNO₃; the pH of the solution was lowered to 2.0 by adding2.4 grams of 1.0 M HNO₃. Lowering the pH of the aqueous solution to 2.0ensured complete solubility of the EEPO polymer in the solution. Thetotal percentage of EEPO to toner was to equal 3% weight of dry toner.

Coating Procedure of EEPO onto Surface of Polyester Toner Particles

The above toner (Toner 1) made up of 85% sodio-sulfonated polyester, 9%Carnauba wax dispersion and 6%-wt of Flexiverse Blue was treated in thelab via a pH shifting procedure where EEPO is soluble or insoluble in anaqueous solution depending on the pH of the aqueous solution.

A 327 gram quantity of the toner slurry (12.9%-weight solids in 87.1%mother liquor) made up of 85% sodio-sulfonated polyester, 9% Carnaubawax dispersion and 6%-wt of Flexiverse Blue pigment was separated fromits mother liquor via decanting, and then stirred in a 1-L glassErlenmeyer flask on a stir plate at 250-300 rpm. The pH of the tonerslurry was lowered from 5.5 to 2.4 by the addition of 70 grams of 0.3 MHNO₃. The EEPO solution was added drop wise to the toner slurry andstirred for 1 hour at room temperature. After 1 hour the pH of the tonerslurry was increased to 12.2 with 71 grams of 1.0 M NaOH and left tostir at 300 rpm for 18 to 20 hours overnight at ambient temperature. Thesurface-treated toner was then filtered and washed four times. Thefiltercake was then resuspended to approximately 25%-wt solids andfreeze-dried. The pH of the filtrates was always greater than 9.5 andshowed no sign of precipitated EEPO; it can be assumed that all EEPOpolymer was transferred to the toner surface. This toner was comprisedof—85% sodio-sulfonated polyester, 9% Carnauba wax dispersion and 6%-wtof Flexiverse Blue pigment with 3% EEPO relative to dry toner weightdeposited or coated on the toner's surface.

Example II Untreated Toners

Preparation of Styrene Butylacrylate Carboxylic Acid Latex: (Latex B)

A latex emulsion (i) comprised of polymer particles generated from theemulsion polymerization of styrene, butyl acrylate and beta carboxyethyl acrylate (Beta CEA) was prepared as follows. A surfactant solutionof 434 grams of DOWFAX 2A1™—disodium dodecyl diphenyloxide disulfonate(anionic emulsifier) and 387 kilograms of deionized water was preparedby mixing for 10 minutes in a stainless steel holding tank. The holdingtank was then purged with nitrogen for 5 minutes before transferring themixture into a reactor. The reactor was then continuously purged withnitrogen while being stirred at 100 RPM. The reactor was then heated to80° C.

Separately, 6.11 kilograms of ammonium persulfate initiator weredissolved in 30.2 kilograms of deionized water. Also, separately amonomer emulsion A was prepared in the following manner. 315.7 Kilogramsof styrene, 91.66 kilograms of butyl acrylate, 12.21 kilograms ofbeta-CEA, 7.13 kilograms of 1-dodecanethiol, 1.42 kilograms ofdecanediol diacrylate (ADOD), 8.24 kilograms of DOWFAX™ (anionicsurfactant), and 193 kilograms of deionized water were mixed to form anemulsion. Five percent of the above emulsion was then slowly fed intothe reactor containing the aqueous surfactant phase at 80° C. to formthe seeds wherein the “seeds” refer, for example, to the initialemulsion latex added to the reactor, prior to the addition of theinitiator solution, while being purged with nitrogen. The aboveinitiator solution was then slowly charged into the reactor, formingabout 5 to about 12 nanometers of latex “seed” particles. After 10minutes, the remainder of the emulsion was continuously fed in usingmetering pumps.

Once all of the above monomer emulsion was charged into the mainreactor, the temperature was maintained at 80° C. for an additional 2hours to complete the reaction. The reactor contents were then cooleddown to about 25° C. The resulting isolated product was comprised of 40weight percent of submicron, 0.5 micron, diameter resin particles ofstyrene/butylacrylate/beta CEA suspended in 60 percent water and 1.5 pphof the anionic surfactant. The molecular properties resulting for theresin latex were M_(w) of 39,000, M_(n) of 10.8, as measured by a GelPermeation Chromatograph, and a midpoint Tg of 55.8° C., as measured bya Differential Scanning Calorimeter, where the midpoint Tg is thehalfway point between the onset and the offset Tg of the polymer.

Preparation of Cross-Linked Latex (Latex C)

A cross-linked latex emulsion comprised of polymer particles generatedfrom the emulsion polymerization of styrene, butyl acrylate and betacarboxy ethyl acrylate (β) CEA was prepared as follows. A surfactantsolution of 4.08 kilograms of NEOGEN™ RK (anionic emulsifier) and 78.73kilograms of deionized water was prepared by mixing these components for10 minutes in a stainless steel holding tank. The holding tank was thenpurged with nitrogen for 5 minutes before transferring the resultingmixture into the above reactor. The reactor was then continuously purgedwith nitrogen while the contents were being stirred at 100 RPM. Thereactor was then heated up to 76° C., and held there for a period of 1hour.

Separately, 1.24 kilograms of ammonium persulfate initiator wasdissolved in 13.12 kilograms of deionized water.

Also separately, monomer emulsion was prepared in the following manner.47.39 Kilograms of styrene, 25.52 kilograms of butyl acrylate, 2.19kilograms of β-CEA, 0.729 kilogram of divinyl benzene (DVB) crosslinkingagent, 1.75 kilograms of NEOGEN™ RK (anionic surfactant), and 145.8kilograms of deionized water were mixed to form an emulsion. One (1)percent of the emulsion was then slowly fed into the reactor, while thereactor was being purged with nitrogen, containing the aqueoussurfactant phase at 76° C. to form “seeds”. The initiator solution wasthen slowly charged into the reactor and after 40 minutes the remainderof the emulsion was continuously fed in using metering pumps over aperiod of 3 hours.

Once all the monomer emulsion was charged into the above main reactor,the temperature was held at 76° C. for an additional 4 hours to completethe reaction. Cooling was then accomplished and the reactor temperaturewas reduced to 35° C. The product was collected into a holding tank.After drying, the resin latex onset Tg was 53.5° C. The resulting latexwas comprised of 25 percent cross-linked resin, 72.5 percent water and2.5 percent anionic surfactant. The resin had a ratio of 65:35:3 pph:1pph of styrene:butyl acrylate:β-CEA:DVB. The mean particle size of thegel latex was 50 nanometers as measured on disc centrifuge, and theresin in the latex possessed a crosslinking value of 25 percent asmeasured by gravimetric method.

Toner 3: White Particles (Non Cross-Linked)

310 grams of the above prepared latex emulsion (latex B) and 164 gramsof an aqueous titanium dioxide (TiO₂) dispersion containing 97 grams ofTiO₂ with a solids loading of 66.6 percent, were simultaneously added to600 milliliters of water with high shear stirring by means of apolytron. To this mixture was added 11.25 grams of a polyaluminumsulfosilicate (PASS) solution containing 1.25 grams of PASS, 10 percentsolids and 10 grams of 0.2 molar nitric acid, over a period of 1 minute,followed by the addition of 11.25 grams of cationic surfactant solutioncontaining 1.25 grams of the coagulant SANIZOL B™ (60 percent activeingredients) and 10 grams of deionized water, and blended at a speed of5,000 rpm for a period of 3 minutes. The resulting mixture wastransferred to a 2 liter reaction vessel and heated at a temperature of47° C. for 120 minutes resulting in aggregates of a size of 6micrometers and a Geometric Standard Deviation (“GSD”) of 1.19. To thetoner aggregates were added 130 grams of the above prepared latexfollowed by stirring for an additional 90 minutes; the temperature washeld at 47° C. The particle size of the aggregates was found to be 6.2with a GSD of 1.19.

The pH of the resulting mixture was then adjusted from 2 to 7.9 withaqueous base solution of 4 percent sodium hydroxide and allowed to stirfor an additional 15 minutes. Subsequently, the resulting mixture washeated to 93° C. and retained there for a period of 1 hour where theparticle size measured was 6.2 micrometers with a GSD of 1.20. This wasfollowed by the reduction of the pH to 5.8 with 4 percent nitric acidsolution and allowed to stir for an additional 40 minutes. The particlesize was 6.2 micrometers with a GSD of 1.20. The pH of the mixture wasfurther decreased to 5, and allowed to coalesce for an additional 1 hourresulting in spherical particles with a size of 6.3 micrometers and aGSD of 1.21. The reactor was then cooled down to room temperature andthe particles were washed 4 times with deionized water. The tonerparticles obtained were comprised of 73 percent styrene butylacrylateBCEA resin and 27 percent titanium pigment, and these particles dried ona freeze dryer at a temperature of −80° C. for a period of 2 days.

Toner 4: White Particle (Cross-Linked)

About 222 grams of the above prepared latex emulsion (latex B) alongwith 88 gm of latex C and 164 grams of an aqueous titanium dioxide(TiO₂) dispersion containing 64 grams of TiO₂ with a solids loading of66.6 percent, and 33.4 percent water were simultaneously added to 600milliliters of water with high shear stirring by means of a polytron. Tothis mixture were added 11.25 grams of a polyaluminum sulfosilicate(PASS) solution containing 1.25 grams of PASS of 10 percent solids ofpolyaluminum sulfosilicate and 10 grams of 0.2 molar nitric acid, over aperiod of 1 minute, followed by the addition of 11.25 grams of acationic surfactant solution containing 1.25 grams of the coagulantSANIZOL B™ (60 percent active ingredients) and 10 grams of deionizedwater and blended at a speed of 5,000 rpm for a period of 3 minutes. Theresulting mixture was transferred to a 2 liter reaction vessel andheated at a temperature of 45° C. for 110 minutes resulting inaggregates of a size diameter of 5.1 micrometers and a GeometricStandard Deviation (“GSD”) of 1.20. To the resulting toner aggregateswere added 130 grams of the above prepared latex followed by stirringfor an additional 90 minutes; the temperature was then increased to 47°C. The particle diameter size of the aggregates was found to be 5.4 anda GSD of 1.19.

The pH of the resulting mixture was then adjusted from about 2 to about7.9 with aqueous base solution of 4 percent sodium hydroxide and allowedto stir for an additional 15 minutes. Subsequently, the resultingmixture was heated to 93° C. and retained there for a period of 1 hourwhere the particle size of the formed aggregates was 5.6 micrometerswith a GSD of 1.21. This was followed by the reduction of the pH to 5.5with 5 percent nitric acid solution and followed by stirring for anadditional 40 minutes. The diameter particle size of the formedaggregates measured was 5.7 micrometers with a GSD of 1.21. The pH ofthe mixture was further decreased to 5 and allowed to coalesce for anadditional 1 hour, resulting in spherical particles with a size diameterof 5.7 micrometers and a GSD of 1.21. The reactor was then cooled downto room temperature, about 22° C. to about 25° C., and the resultingparticles were washed 4 times with deionized water with the final washat a pH of 4. The particles were then dried on a freeze dryer at atemperature of −80° C. for a period of 2 days. The toner particlesobtained were comprised of 60 percent styrene butylacrylate BCEA, 20percent styrene butylacrylate BCEA, bivinylbenzene resin and 20 percenttitanium dioxide pigment.

Toner 5: Magenta Toner

Similarly, a 6.2 micron magenta toner containing 6 percent pigmentcontaining 60% PR 122, and 40 percent PR 238 was prepared using theprocedure set forth in Example 2.

Toner 6: Yellow Toner

Similarly, a 6.5 micron magenta toner containing 8 percent pigment (PY74) was prepared using the procedure set forth in Example 2.

Toner 7: Black Toner

Similarly, a 6.8 micron black toner containing 6% Regal 330 was preparedusing the procedure set forth in Example 2. The toner comprised 85%sodio-sulfonated polyester, 9% Carnauba wax dispersion and 6% (byweight) of Regal 330 pigment with 3% EEPO relative to dry toner weightdeposited or water on the toner's surface.

Display Testing

The above toners were identified as candidate materials for dry-powderelectrophoretics. The following toner combinations were tested in aparallel plate cell as follows. A small quantity of positive andnegatively charged toner particles (around 10-20 mg each) were added toa glass vial, followed by 5-10 mg of 25 um glass fiber spacer particles.The toner and fiber mixture was thoroughly mixed with a small spatula,and the mixture was applied to a 2×2 inch ITO coated glass plate bytapping. The powder was spread by hand to create a uniform coating onthe ITO coated glass surface. The coated glass plate was covered with asecond glass plate and the two plates were rubbed back and forth againstone another to further spread the toner mixture, and evenly distributethe spacer fibers. The two plates were finally secured together usingbinder clips.

NEGATIVELY POSITIVELY CHARGED CHARGED TONER Sample TONER PARTICLESPARTICLES 1 Toner 5 Toner 2 2 Toner 6 Toner 2 3 Toner 3 (4) Toner 2

The above toner combinations showed good color coverage when the voltageof the cell is switched. A square waveform voltage of +/−200V withfrequency of 300 mHz was applied across the two ITO coated glass plates,and a distinct contrast was observed as the toner particles migratedback and forth across the cell gap.

Example 3

A dry-powder cell was prepared with ITO glass electrodes coated withsilicone sealant spray. White toner particles (Toner 3) and black tonerparticles (Toner 7) were used in the cell. A voltage of about 80 toabout 90 volts was applied across the cell, and an AC field overlay of80 volts with a frequency of 300 Hertz was applied simultaneously. Thecell shows good coverage of the black and white colors as the voltage isswitched.

The use of emulsion aggregation particles in an electrophoretic displayincluding emulsion aggregation particles with a surface coating toimpart a positive charge to select particles as described hereinprovides a satisfactory dry-powder electrophoretic display. Improveddevice performance is realized in that the highly cross-linked tonerparticles are more resistant to melting and agglomeration as compared toconventional “inks.” Additionally, modifying the surface of some tonerparticles with a surface coating, as described herein, allows forselective tuning of the surface charge to be positive or negative.

While particular embodiments have been described, alternatives,modifications, variations, improvements, and substantial equivalentsthat are or may be presently unforeseen may arise to applicants orothers skilled in the art. Accordingly, the appended claims as filed andas they may be amended are intended to embrace all such alternatives,modifications variations, improvements, and substantial equivalents.

1. A dry-powder electrophoretic display comprising: a pair of electrodesdisposed opposite one another; a spacer layer disposed between theelectrodes and defining an air gap therebetween; a first set of drytoner particles comprising a plurality of toner particles of a firstcolor and a first charge; and a second set of dry toner particlescomprising a plurality of toner particles of a second color and a secondcharge; wherein the toner particles of the second sets of dry tonerparticles comprises a surface coating disposed on the surface of thetoner particles, said surface coating comprising a polymer selected fromthe group of methacrylate polymers and polycarbonate polymers, andimparting a positive charge to the toner particles.
 2. The dry-powderelectrophoretic display according to claim 1, wherein said surfacecoating is a methacrylate polymer.
 3. The dry-powder electrophoreticdisplay according to claim 2, wherein said methacrylate polymer is acopolymer ofbutylmethacrylate-(2-dimethylaminoethyl)-methacrylate-methylmethacrylate.4. The dry-powder electrophoretic display according to claim 3, whereinthe ratio of butylmethacrylate:(2-dimethylaminoethyl)methacrylate:methylmethacrylate is about 1:2:1.
 5. The dry-powderelectrophoretic display according to claim 1, wherein said surfacecoating is present in an amount of about 1 to about 10% by weight of thetoner particles upon which the coating is disposed.
 6. The dry-powdereletrophoretic display according to claim 1, wherein said surfacecoating is present in an amount of from about 3 to about 7% by weight ofthe toner particles upon which the coating is disposed.
 7. Thedry-powder electrophoretic display according to claim 1, wherein thetoner particles comprising the surface coating have a particle size fromabout 1 to about 20 microns.
 8. The dry-powder electrophoretic displayaccording to claim 3, wherein the toner particles comprising the surfacecoating have a particle size of from about 1 to about 10 microns.
 9. Thedry-powder electrophoretic display according to claim 3, wherein thetoner particles comprising the surface coating have a particle size offrom about 4 to about 7 microns.
 10. A dry-powder electrophoreticdisplay comprising: a cell having a viewed region and a non-viewedregion, a plurality of first toner particles having a first electricalcharge, said first toner particles comprising a resin and a colorant;and a plurality of second toner particles having a second electricalcharge, said second toner particles comprising a resin, a colorant and asurface coating disposed on the outer surface of the particles; whereinsaid surface coating comprises a methacrylate polymer and imparts apositive charge to the second toner.
 11. The dry-powder electrophoreticdisplay according to claim 10, wherein said methacrylate polymer is acopolymer ofbutylmethacrylate-(2-dimethylaminoethyl)-methacrylate-methylmethacrylate.12. The dry-powder electrophoretic display according to claim 11,wherein the ratio of butylmethacrylate:(2-dimethylaminoethyl)methacrylate:methylmethacrylate isabout 1:2:1.
 13. The dry-powder electrophoretic display according toclaim 10, wherein said surface coating is present in an amount of about1 to about 10% by weight of the toner particles upon which the coatingis disposed.
 14. The dry-powder eletrophoretic display according toclaim 10, wherein said surface coating is present in an amount of fromabout 3 to about 7% by weight of the toner particles upon which thecoating is disposed.
 15. The dry-powder electrophoretic displayaccording to claim 10, wherein the toner particles comprising thesurface coating have a particle size from about 1 to about 20 microns.16. The dry-powder electrophoretic display according to claim 11,wherein the toner particles comprising the surface coating have aparticle size of from about 1 to about 10 microns.
 17. The dry-powderelectrophoretic display according to claim 11, wherein the tonerparticles comprising the surface coating have a particle size of fromabout 4 to about 7 microns.
 18. A dry-powder electrophoretic displaycomprising: a first electrode; a second electrode disposed opposite thefirst electrode; a spacer layer disposed between the first and secondelectrodes, the space layer creating an air gap between the first andsecond electrode; a first set of toner particles disposed between thefirst and second electrodes, the first set of toner particles comprisinga resin and a colorant, and having a negative charge; and a second setof toner particles disposed between the first and second electrodes, thesecond set of toner particles comprising a resin and a colorant, andhaving a positive charge, wherein the positive charge is produced by theapplication to the second set of toner particles, a surface coating, inan amount of from about 1 to about 10 percent by weight of the tonerparticles, formed from a methacrylate polymer comprising a copolymer ofbutylmethacrylate/(2-dimethylaminoethyl)methacrylate/methylmethacrylate.19. The dry-powder electrophoretic display according to claim 18,wherein the toner particles of each of the first and second sets oftoner particles have a particle size of from about 1 to about 20microns.
 20. The dry-powder electrophoretic display according to claim18, wherein the toner particles of each of the first and second sets oftoner particles have a particle size of about 10 microns or less. 21.The dry-powder electrophoretic display according to claim 18, whereinthe surface coating is present in an amount of from about 3 to about 7percent by weight of the toner particles.
 22. The dry-powderelectrophoretic display according to claim 18, wherein the ratio ofbuylmethacrylate to (2-dimethylaminoethyl)methacrylate tomethylmethacrylate is about 1:2:1.
 23. A process for preparing a drytoner composition for use in a dry-powder electrophoretic display, theprocess comprising: forming a first set of dry toner particlescomprising a resin and a colorant by an emulsion aggregation process,said first set of dry toner particles having a negative charge; andforming a second set of dry toner particles comprising a resin latex anda colorant, the second set of dry toner particles being formed byheating a mixture of a latex and a colorant at a temperature of belowabout the glass transition temperature (Tg) of a polymer contained inthe latex; and cooling the mixture; wherein said second set of dry tonerparticles is further wet surface treated with a methacrylate polymer byadding a methacrylate polymer solution to the mixture of the latex andcolorant subsequent to the cooling of the latex and colorant mixture,and adjusting the pH of the resulting solution to above about 7 therebypermitting the methacrylate polymer to precipitate on the tonerparticles, said methacrylate polymer providing a positive charge to thesurface of the toner particles of the second set of dry toner particles.24. A process in accordance with claim 23, wherein said methacrylatepolymer is abutylmethacrylate-(2-dimethylaminoethyl)methacrylate-methylmethacrylatecopolymer (1:2:1) comprising (2-dimethylaminoethyl) methacrylate, butylmethacrylate and methyl methacrylate, the methacrylate polymer having amean molecular weight, Mw, of from about 125,000 to about 175,000.
 25. Aprocess in accordance with claim 23, wherein said methacrylate polymeris present in an amount of from about 1 to about 10 weight percent. 26.A process in accordance with claim 23, wherein said methacrylate polymeris present in an amount of from about 3 to about 7 weight percent.
 27. Aprocess in accordance with claim 23, wherein said methacrylate polymeris abutylmethacrylate-(dimethylaminoethyl)methacrylate/methylmethacrylatecopolymer present in an amount of from about 1 to about 10 weightpercent.
 28. A process in accordance with claim 23, wherein saidmethacrylate polymer is abutylmethacrylate-(dimethylaminoethyl)methacrylate/methylmethacrylatecopolymer present in an amount of from about 3 to about 7 weightpercent.
 29. A process in accordance with claim 23, wherein said pH isfrom about 8 to about
 12. 30. A process in accordance with claim 23,wherein said pH is from about 10 to about
 11. 31. A process inaccordance with claim 29, wherein the pH of the resulting mixture afterheating is from about 2 to about 5 and which pH is increased to fromabout 9 to about 12 subsequent to the addition of said methacrylate. 32.A process in accordance with claim 29, wherein the pH of the resultingmixture after heating is from about 2 to about 4 and which pH isincreased to from about 10 to about 12 subsequent to the addition ofsaid methacrylate.
 33. A process in accordance with claim 23, furthercomprising a second heating at a temperature of about 70° C. to about95° C. and wherein coalescence results for said latex resin, saidcolorant and said methacrylate, and which methacrylate is present on thesurface of said resulting toner.